[email protected] +1 (925) 687-4411over load vin = 24v, load 0% to 100% 0.05 0.10 % temperature...

www.calex.com FXW.A01 1

a division of

FXW Series, 1000 Watt

[email protected] +1 (925) 687-4411

DC/DC Converters

The 4:1 Input Voltage 1000 Watt Single FXW DC/DC converter provides a precisely regulated dc output. The output voltage is fully isolated from the input, allowing the output to be positive or negative polarity and with various ground connections. The 1000 Watt FXW meets the most rigorous performance standards in an industry standard footprint for mobile (12Vin), process control (24Vin), and military COTS (28Vin) applications.

The 4:1 Input Voltage 1000W FXW includes trim and remote ON/OFF. Threaded through holes are provided to allow easy mounting or addition of a heatsink for extended temperature operation.

The converters high efficiency and high power density are accomplished through use of high-efficiency synchronous rectification technology, advanced electronic circuit, packaging and thermal design thus resulting in a high reliability product. Converter operates at a fixed frequency and follows conservative component de-rating guidelines.

• 4:1 Input voltage range

• High power density

• Small size 2.5” x 4.7” x 0.52”

• Efficiency up to 96%

• Excellent thermal performance with metal baseplate

• Over-Current and Short Circuit Protection

• Over-Temperature protection

• Auto-restart

• Monotonic startup into pre bias

• Constant frequency

• Remote ON/OFF

• Good shock and vibration damping

• Temperature Range -40ºC to +105ºC Available.

• RoHS Compliant

• UL60950 Approved

Features

Table of ContentsPart Number Selection Table & Description . . . . . . . 2Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Test Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Characteristic Curves . . . . . . . . . . . . . . . . . . . . . . . . . . .16Characteristic Waveforms . . . . . . . . . . . . . . . . . . . . . .20EMC Consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25Mechanical Specification . . . . . . . . . . . . . . . . . . . . . . . .26

FXW.A01 2Calex Manufacturing Company, Inc., a division of Murata Power Solutions

DC/DC Converters


Part Number Selection Table

Voltage (VDC) CurrentEfficiency

Ripple & Noise

RegulationCapacitive

LoadRoot Model

Input Output Input Output

Vin Nom

Vin RangeVout Nom

No Load (mA)

Max Load (A)

Io Max (A)

Typical at Max Load

(%)

Typical (mVp-p)

Line / LoadMax (%)

Max. Cexternal (µF)

Basic Model without option

24 9 – 36

12 .55 92 84 93 120 .05/.05 4700 24S12.84FXW

24 .42 92 42 94.6 200 .05/.05 4700 24S24.42FXW

28 .55 92 36 95.5 220 .05/.05 4700 24S28.36FXW

48 .47 92 21 95 100 .05/.05 3000 24S48.21FXW

53 .46 92 19 95 70 .05/.05 2200 24S53.19FXW

1. Negative Logic ON/OFF feature available. Add “-N” to the part number when ordering. i.e. 24S24.42FXW-N (ROHS)

2. Designed to meet MIL-STD-810G for functional shock and vibration. The unit must be properly secured to the interface medium (PCB/Chassis) by use of the threaded inserts of the unit.

3. A thermal management device, such as a heatsink, is required to ensure proper operation of this device. The thermal management medium is required to maintain baseplate < 105ºC for full rated power.

4. Non-Standard output voltages are available. Please contact the factory for additional information.

Part Number Description


DC/DC Converters


Electrical Specifications

Conditions: TA = 25 ºC, Airflow = 300 LFM (1.5 m/s), Vin = 24VDC, unless otherwise specified. Specifications are subject to change without notice.

All ModelsParameter Notes Min Typ Max Units

Absolute Maximum Ratings

Input VoltageContinuous 0 40 V

Transient (100ms) 50 V

Operating Temperature Baseplate (100% load) -40 105 °C

Storage Temperature -55 125 °C

Isolation Characteristics and Safety

Isolation VoltageInput to Output 2250 V

Input to Baseplate & Output to Baseplate 1500 V

Isolation Capacitance 9000 pF

Isolation Resistance 10 20 MΩ

Insulation Safety Rating Basic

Designed to meet UL/cUL 60950, IEC/EN 60950-1

Feature Characteristics

Fixed Switching Frequency 200 kHz

Input Current and Output Voltage Ripple 400 kHz

Output Voltage Trim Range Adjustable via TRIM (Pin 12) 60 110 %

Remote Sense Compensation Between SENSE+ and +OUT pins 1 V

Output Overvoltage Protection Non-latching 114 122 130 %

Overtemperature Shutdown (Baseplate) Non-latching (Vin=9V; 12V, 24/36V) 108 112 115 °C

Auto-Restart Period Applies to all protection features 1.7 2 2.3 s

Turn-On Delay Time from VinTime from UVLO to VO=90%VOUT (NOM) Resistive load

480 517 530 ms

Turn-On Delay Time from ON/OFF Control(From ON to 90% VOUT (NOM) Resistive load)

24S24.42FXW & 24S28.36FXW 20 27 35 ms

24S48.21FXW & 24S53.19FXW 20 35 50 ms

Rise Time (Vout from 10% to90%)24S24.42FXW & 24S28.36FXW 4 7 11 ms

24S48.21FXW & 24S53.19FXW 7 15 25 ms

ON/OFF Control – Positive Logic

ON state Pin open = ON or 2 12 V

Control Current Leakage current 0.16 mA

OFF state 0 0.8 V

Control current Sinking 0.3 0.36 mA

ON/OFF Control – Negative Logic

ON state Pin shorted to – ON/OFF pin or 0 0.8 V

OFF state Pin open = OFF or 2 12 V

Thermal Characteristics

Thermal resistance Baseplate to AmbientConverter soldered to 5” x 3.5” x 0.07”,4 layers/ 2Oz copper FR4 PCB.

3.3 °C/W


DC/DC Converters


Electrical Specifications (Continued):

Conditions: TA = 25 ºC, Airflow = 300 LFM (1.5 m/s) and 0.9” heatsink, Vin = 14VDC, unless otherwise specified. Specifications are subject to change without notice.

24S12.84FXWParameter Notes Min Typ Max Units

Input Characteristics

Operating Input Voltage Range 9 14 36 V

Input Under Voltage Lockout Non-latching

Turn-on Threshold 8.2 8.5 8.8 V

Turn-off Threshold 7.7 8.0 8.3 V

Lockout Hysteresis Voltage 0.4 0.55 0.7 V

Maximum Input Current Vin = 9V, 80% Load 89 A

Vin = 12V, 100% Load 92 A

Vin = 14V, Output Shorted 600 mARMS

Input Stand-by Current Converter Disabled 2 4 mA

Input Current @ No Load Converter Enabled 450 550 690 mA

Minimum Input Capacitance (external)1 See Table 1 1000 µF

Inrush Transient 0.19 A2s

Input Terminal Ripple Current, iC 25 MHz bandwidth, 100% Load (Fig. 2) 3.65 ARMS

Output Characteristics

Output Voltage Range 11.64 12.00 12.36 V

Output Voltage Set Point Accuracy (No load) 11.90 12.00 12.10 V

Output Regulation

Over Line Vin = 9V to 36V 0.05 0.10 %

Over Load Vin = 14V, Load 0% to 100% 0.05 0.150 %

Temperature Coefficient 0.005 0.015 %/ºC

Overvoltage Protection 14 15.6 V

Output Ripple and Noise – 20 MHz bandwidth 100% Load,See Table 1 for external components

120 mVPK-PK

40 mVRMS

External Load Capacitance1) See Table 1

Output Current Range (See Fig. A)Vin = 12V – 36V 0 84 A

Vin = 9V 0 67.2 A

Current Limit InceptionVin = 12V – 36V 92.4 100.8 109.2 A

9V ≤ Vin < 12V 73.5 109.2 A

RMS Short-Circuit Current Non-latching, Continuous 7 ARMS

Dynamic Response

Load Change 50%-100%-50%, di/dt =0 .5A/µs See Table 1 for external capacitors ±500 mV

Settling Time to 1% of VOUT 800 µs

Efficiency

100% LoadVin = 14V 93.0 %

Vin = 12V 92.3 %

50% Load Vin = 14V 95.4 %

Vin = 12V 95.0 %

1) Section “Input and Output Capacitance”


DC/DC Converters





Input CharacteristicsOperating Input Voltage Range 9 24 36 V





Maximum Input Current

Vin = 9V, 80% Load 89 A

Vin = 12V, 100% Load 92 A




Minimum Input Capacitance (external)1 ESR < 0.1 Ω 1000 µF



Output CharacteristicsOutput Voltage Range 23.62 24.00 24.36 V


Output Regulation




Overvoltage Protection 27.36 31.2 V


200 320 mVPK-PK

50 80 mVRMS

External Load Capacitance1 Full Load (resistive)(over operating temp range)

CEXT 1000 4700 µFmΩESR 10 100


Vin = 9V 0 33.5 A

Current Limit InceptionVin = 12V – 36V 46 50.2 54.6 A

9V ≤ Vin < 12V 37 49 54.6 A

RMS Short-Circuit Current Non-latching, Continuous 2.0 3.1 6.5 ARMS

Dynamic ResponseLoad Change 50%-75%-50%, di/dt = 1A/µs CO = 2 x 470 µF/70mΩ ± 400 ± 600 mV

Load Change 50%-100%-50%, di/dt = 1A/µs CO = 2 x 470 µF/70mΩ ±700 mV


Efficiency

100% LoadVin = 24V 93.6 94.6 95.3 %

Vin = 12V 92.4 93.4 94 %

50% Load Vin = 24V 95.0 96 96.4 %

Vin = 12V 94.7 95.7 96.3 %1) Section “Input and Output Capacitance”


DC/DC Converters












Vin = 9V, 80% Load 89 A

Vin = 12V, 100% Load 92 A










Output Regulation






220 360 mVPK-PK

50 80 mVRMS


CEXT 1000 4700 µFmΩESR 10 100


Vin = 9V 0 28.8 A

Current Limit InceptionVin = 12V – 36V 39.6 46.8 A

9V ≤ Vin < 12V 31.7 46.8 A


Dynamic Response

Load Change 50%-75%-50%, di/dt = 1A/µs See Table 1 for external components ± 330 ± 430 mV

Load Change 50%-100%-50%, di/dt = 1A/µs See Table 1 for external components ±600 mV


Efficiency

100% LoadVin = 24V 94.5 95.5 96.2 %

Vin = 12V 93.0 93.8 94.5 %

50% Load Vin = 24V 95.5 96.2 97 %



DC/DC Converters





Input CharacteristicsOperating Input Voltage Range 9 24 36 V






Vin = 9V, 80% Load 89 A

Vin = 12V, 100% Load 92 A










Output Regulation






100 150 mVPK-PK

25 50 mVRMS


CEXT 470 3000 µFmΩESR 10 100


Vin = 9V 0 16.8 A


9V ≤ Vin < 12V 18.48 20.16 27.3 A


Dynamic Response


Load Change 50%-100%-50%, di/dt = 1A/µs See Table 1 for external components ±880 ±1150 mV


Efficiency

100% LoadVin = 24V 94.3 95.0 95.7 %

Vin = 12V 93.2 93.9 94.6 %

50% Load Vin = 24V 95.3 96 96.7 %



DC/DC Converters












Vin = 9V, 80% Load 89 A

Vin = 12V, 100% Load 92 A










Output Regulation




Overvoltage Protection 60.4 64.7 69.4 V


70 140 mVPK-PK

16 50 mVRMS

External Load Capacitance1 Full Load (resistive) (over operating temp range)

CEXT 470 2200 µFmΩESR 10 100


Vin = 9V 0 15.2 A


9V ≤ Vin < 12V 16.7 18.2 24.7 A


Dynamic Response


Load Change 50%-100%-50%, di/dt = 1A/µs See Table 1 for external components ±850 ±1100 mV


Efficiency

100% LoadVin = 24V 94.9 95.7 96.4 %

Vin = 12V 93.4 94.1 95 %

50% Load Vin = 24V 95.3 96.2 96.9 %



DC/DC Converters


Environmental and Mechanical Specifications. Specifications are subject to change without notice.

Parameter Note Min Typ Max Units

Environmental

Operating Humidity Non-condensing 95 %

Storage Humidity Non-condensing 95 %

ROHS Compliance1 See Calex Website http://www.calex.com/RoHS.html for the complete RoHS Compliance statement

Shock and Vibration Designed to meet MIL-STD-810G for functional shock and vibration.

Water washability Not recommended for water wash process. Contact the factory for more information.

Mechanical

Weight8.55 Ounces

242 Grams

Through Hole Pins Diameter

Pins 3, 3A, 4, 4A, 5, 6, 8 and 90.079 0.081 0.083 Inches

2.006 2.057 2.108 mm

Pins 1, 2, 10, 11 and 120.038 0.04 0.042 Inches

0.965 1.016 1.067 mm

Through Hole Pins MaterialPins 3, 3A, 4, 4A, 5, 6 , 8 and 9 14500 or C1100 Copper Alloy

Pins 1, 2, 10, 11 and 12 TB3 or “Eco Brass”

Through Hole Pin Finish All pins 10µ” Gold over nickel

Case Dimension4.7 x 2.5 x 0.52 Inches

119.38 x 63.50 x 13.21 mm

Case Material Plastic: Vectra LCP FIT30: ½-16 EDM FinishPlastic

Baseplate

Material Aluminum

Flatness 0.010 Inches

0.25 mm

Reliability

MTBF Telcordia SR-332, Method I Case 1 50% electrical stress, 40°C components 5.4 MHrs

Agency Approvals UL60950 Approved

EMI and Regulatory Compliance

Conducted Emissions MIL-STD 461F CE102 with external EMI filter network (See Figs. 57 and 58)

Additional Notes:

1 The RoHS marking is as follows

0

200

400

600

800

1000

1200

9 12 15 18 21 24 27 30 33 36

Out

put P

ower

[W]

Input Voltage [V]

Output Power vs. Input Voltage

Figure A: Output Power as function of input voltage.


DC/DC Converters


OperationsInput Fusing

The FXW converters do not provide internal fusing and therefore in some applications external input fuse may be required. Use of external fuse is also recommended if there is possibility for input voltage reversal. For greatest safety, it is recommended to use fast blow fuse in the ungrounded input supply line.

Input Reverse Polarity Protection

The FXW converters do not have input reverse polarity. If input voltage polarity is reversed, internal diodes will become forward biased and draw excessive current from the power source. If the power source is not current limited or input fuse not used, the converter could be permanently damaged.

Input Undervoltage Protection

Input undervoltage lockout is standard with this converter. The FXW converter will start and regulate properly if the ramping-up input voltage exceeds Turn-on threshold of typ. 8.5V (See Specification) and remains at or above Turn-on Threshold.

The converter will turn off when the input voltage drops below the Turn-off Threshold of typical 8V (See specification) and converter enters hiccup mode and will stay off for 2 seconds. The converter will restart after 2 seconds only if the input voltage is again above the Turn-on Threshold.

The built-on hysteresis and 2 second hiccup time prevents any unstable on/off operation at the low input voltage near Turn-on Threshold.

User should take into account for IR and inductive voltage drop in the input source and input power lines and make sure that the input voltage to the converter is always above the Turn-off Threshold voltage under ALL OPERATING CONDITIONS.

Start-Up Time

The start-up time is specified under two different scenarios: a) Startup by ON/OFF remote control (with the input voltage above the Turn-on Threshold voltage) and b) Start-up by applying the input voltage (with the converter enabled via ON/OFF remote control).

The startup times are measured with maximum resistive load as: a) the interval between the point when the ramping input voltage crosses the Turn-on Threshold and the output voltage reaches 90% of its nominal value and b) the interval between the point when the converter is enabled by ON/OFF remote control and time when the output voltage reaches 90% of its nominal value.

When converter is started by applying the input voltage with ON/OFF pin active there is delay of 500msec that was intentionally provided to prevent potential startup issues especially at low input voltages

Input Source Impedance

Because of the switching nature and negative input impedance of DC/DC converters, the input of these converters must be driven from the source with both low AC impedance and DC input regulation.

The FXW converters are designed to operate without external components as long as the source voltage has very low impedance and reasonable voltage regulation. However, since this is not the case in most applications an additional input capacitor is required to provide proper operations of the FXW converter. Specified values for input capacitor are recommendation and need to be adjusted for particular application. Due to large variation between applications some experimentation may be needed.

In many applications, the inductance associated with the distribution from the power source to the input of the converter can affect the stability and in some cases, if excessive, even inhibit operation of the converter. This becomes of great consideration for input voltage at 12V or below.

The DC input regulation, associated with resistance between input power source and input of the converter, plays significant role in particular in low input voltage applications such as 12V battery systems.

Note that input voltage at the input pins of the connector must never degrade below Turn-off threshold under all load operating conditions.

Note that in applications with high pulsating loads additional input as well as output capacitors may be needed. In addition, for EMI conducted measurement, due to low input voltage it is recommended to use 5µH LISNs instead of typical 50µH LISNs.


DC/DC Converters


Input/Output Filtering

Input Capacitor

Minimum required input capacitance, mounted close to the input pins of the converter, is 1000µF with ESR < 0.1Ω.

Several criteria need to be met when choosing input capacitor: a) type of capacitor, b) capacitance to provide additional energy storage, c) RMS current rating, d) ESR value that will ensure that output impedance of the input filter is lower than input impedance of the converter and its variation over the temperature.

Since inductance of the input power cables could have significant voltage drop due to rate of change of input current di(in)/dt during transient load operation, an external capacitor on the output of the converter is required to reduce di(in)/dt. Another constraint is minimum rms current rating of the input capacitors which is application dependent. One component of input rms current handled by input capacitor is high frequency component at switching frequency of the converter (typ. 400kHz) and is specified under “Input terminal ripple current” iC. Typical values at full rated load and 24 Vin are provided in Section “Characteristic Waveforms” for each model and are in range of 2.5A– 3.6A . It is recommended to use ceramic capacitors for attenuating this component for input terminal ripple current, which is also required to meet requirement for conducted EMI (See EMI Section). The second component of the input ripple current is due to pulsating load current being reflected to the input and electrolytic capacitors usually used for this purpose need to be selected accordingly. Using several electrolytic capacitors in parallel on the input is recommended.

ESR of the electrolytic capacitors, need to be carefully chosen taken into account temperature dependence.

Output Capacitor

Similar considerations apply for selecting external output capacitor. For additional high frequency noise attenuation use of ceramic capacitors is recommended while in order to provide stability of the converter during high pulsating load high value electrolytic capacitor is required. It is recommended to use several electrolytic capacitors in parallel in order to reduce effective ESR. Note that external output capacitor also reduces slew rate of the input current during pulsating load transients as discussed above.

Table 1 shows recommend external output capacitance.

ON/OFF (Pins 1 and 2)

The ON/OFF pin is used to turn the power converter on or off remotely via a system signal and has positive logic. A typical connection for remote ON/OFF function is shown in Fig. 1.

Fig.1: Circuit configuration for ON/OFF function.

The positive logic version turns on when the ON/OFF pin is at logic high and turns off when at logic low. The converter is on when the ON/OFF pin is either left open or external voltage greater than 2V and not more than 12V is applied between ON/OFF pin and – INPUT pin. See the Electrical Specifications for logic high/low definitions.

The negative logic version turns on when the ON/OFF pin is at logic low and turns off when at logic high. The converter is on when the ON/OFF pin is either shorted to –INPUT pin or kept below 0.8V. The converter is off when the ON/OFF pin is either left open or external voltage not more than 12V is applied between ON/OFF pin and –INPUT pin. See the Electrical Specifications for logic high/low definitions.

The ON/OFF pin is internally pulled up to typically 4.5V via resistor and connected to internal logic circuit via RC circuit in order to filter out noise that may occur on the ON/OFF pin. A properly de-bounced mechanical switch, open-collector transistor, or FET can be used to drive the input of the ON/OFF pin. The device must be capable of sinking up to 0.36mA at a low level voltage of ≤ 0.8 V. During logic high, the typical maximum voltage at ON/OFF pin (generated by the converter) is 4.5V, and the maximum allowable leakage current is 160µA. If not using the remote on/off feature leave the ON/OFF pin open.

TTL Logic Level - The range between 0.81V and 2V is considered the dead-band. Operation in the dead-band is not recommended.

External voltage for ON/OFF control should not be applied when there is no input power voltage applied to the converter.


DC/DC Converters


Output Overcurrent Protection (OCP)

The converter is protected against overcurrent or short circuit conditions. Upon sensing an overcurrent condition, the converter will switch to constant current operation and thereby begin to reduce output voltage. When the output voltage drops below approx. 50% of the nominal value of output voltage, the converter will shut down.

Once the converter has shut down, it will attempt to restart nominally every 2 seconds. The attempted restart will continue indefinitely until the overload or short circuit conditions are removed or the output voltage rises above 50% of its nominal value.

Once the output current is brought back into its specified range, the converter automatically exits the hiccup mode and continues normal operation.

During initial startup if output voltage does not exceed typical 50% of nominal output voltage within 500 msec after the converter is enabled, the converter will be shut down and will attempt to restart after 2 seconds.

In case of startup into short circuit, internal logic detects short circuit condition and shuts down converter typical 5 msec after condition is detected. The converter will attempt to restart after 2 seconds until the short circuit condition is removed.

Output Overvoltage Protection (OVP)

The converter will shut down if the output voltage across +OUT (Pins 5 and 6) and –OUT (Pins 8 and 9) exceeds the threshold of the OVP circuitry. The OVP circuitry contains its own reference, independent of the output voltage regulation loop. Once the converter has shut down, it will attempt to restart every 2 seconds until the OVP condition is removed.

Note that OVP threshold is set for nominal output voltage and not trimmed output voltage value or remote sense voltage.

Over temperature Protection (OTP)

The FXW converters have non-latching overtemperature protection. It will shut down and disable the output if temperature at the center of the base plate exceeds a threshold of typical 108ºC for 9Vin, 112 ºC for 12Vin and 115 ºC for 24Vin/36Vin. Measured with FXW converter soldered to 5” x 3.5” x 0.07” 4 layers/ 2 Oz Cooper FR4 PCB.

The converter will automatically restart when the base temperature has decreased by approximately 20ºC.

Safety Requirements

Basic Insulation is provided between input and the output. The converters have no internal fuse. To comply with safety agencies requirements, a fast-acting or time-delay fuse is to be provided in the unearthed lead. Recommended fuse values are:

a) 140A for 9V<Vin<18V

b) 90A for 18V<Vin<36V.

Electromagnetic Compatibility (EMC)

EMC requirements must be met at the end-product system level, as no specific standards dedicated to EMC characteristics of board mounted component dc-dc converters exist.

With the addition of a two stage external filter, the FXW converters will pass the requirements of MILSTD-461F CE102 Base Curve for conducted emissions. Note that 5uH LISN should be used in order to enable operation of the converter at low input voltage.

Remote Sense Pins (Pins 10 and 11)

Sense inputs compensate for output voltage inaccuracy delivered at the load.

Fig. 2: Circuit configuration for Remote sense function.

The sense input and power Vout pins are internally connected through 100Ω (SENSE+ to +OUT) and 10 Ω (SENSE- to –OUT) resistors enabling the converter to operate without external connection to the Sense. If the Sense function is not used for remote regulation, the user should connect SENSE- (Pin 10) to –OUT (Pins 8 and 9) and SENSE+ (Pin 11) to +OUT (Pins 5 and 6) at the converter pins.


DC/DC Converters


Sense lines must be treated with care in PCB layouts and should run adjacent to DC signals. If cables and discrete wiring is used, it is recommended to use twisted pair, shielded tubing or similar techniques.

The maximum voltage difference between Sense inputs and corresponding power pins should be kept below 1V, i.e.:

V(SENSE+) - V(+OUT) ≤ 1V V(-OUT) – V(SENSE-) ≤ 1V

Note that maximum output power is determined by maximum output current and highest output voltage at the output pins of the converter:

[V(+OUT) – V(-OUT)]x Iout ≤ Pout rated

Output Voltage Adjust/TRIM (Pin 12)

The TRIM (Pin 12) allows user to adjust output voltage 10% up or -40% down relative to rated nominal voltage by addition of external trim resistor. Trim resistor should be mounted close to the converter and connected with short leads. Internal resistor in the converter used for the TRIM is high precision 0.1% with temperature coefficient 25 ppm/ ºC. The accuracy of the TRIM is therefore determined by tolerance of external Trim resistor. If trimming is not used, the TRIM pin should be left open.

Trim Down – Decrease Output Voltage

Trimming down is accomplished by connecting an external resistor, Rtrim-down, between the TRIM (pin 12) and the SENSE- (pin 10), with a value of:

RTRIM-DOWN = 499∆−9.98 [kΩ]

Where,

RTRIM-DOWN = Required value of the trim-down resistor [kΩ] VO(NOM) = Nominal value of output voltage [V] VO(REQ) = Required value of output voltage [V]

∆ = VO(REQ)−VO(NOM) VO(NOM) [%]

Fig. 3: Circuit configuration for Trim-down function

To trim the output voltage 10% (∆=10) down, required external trim resistance is:

RTRIM-DOWN = 49910−9.98= 39.92 kΩ

Trim Up – Increase Output Voltage

Trimming up is accomplished by connecting an external resistor, RTRIM-UP, between the TRIM (pin 12) and the SENSE+ (pin 11), with a value of:

RTRIM-UP = 4.99*VONOM*(100+∆)1.25∆−(100+2∆)∆ [kΩ]

Fig. 4: Circuit configuration for Trim-up function

To trim the output voltage up, for example 24V to 26.4V, ∆=10 and required external resistor is:

RTRIM-UP = 4.99*24*100+101.25*10−100+2*1010=1015 kΩ

Note that trimming output voltage more than 10% is not recommended and OVP may be tripped.

Active Voltage Programming

In applications where output voltage need to be adjusted actively, an external voltage source, such as for example a Digital-to-Analog converter (DAC), capable of both sourcing and sinking current can be used. It should be connected across with series resistor Rg across TRIM (Pin 12) and SENSE- (Pin 10). External trim voltage should not be applied before converter is enabled in order to provide proper startup output voltage waveform and prevent tripping overvoltage protection. Please contact Calex technical representative for more details.

Thermal Consideration

The FXW converter can operate in a variety of thermal environment. However, in order to ensure reliable operation of the converter, sufficient cooling should be provided. The FXW converter is encapsulated in plastic case with metal baseplate on the top. In order to improve thermal


DC/DC Converters


performance, power components inside the unit are thermally coupled to the baseplate. In addition, thermal design of the converter is enhanced by use of input and output pins as heat transfer elements. Heat is removed from the converter by conduction, convection and radiation.

There are several factors such as ambient temperature, airflow, converter power dissipation, converter orientation how converter is mounted as well as the need for increased reliability that need to be taken into account in

order to achieve required performance. It is highly recommended to measure temperature in the middle of the baseplate in particular application to ensure that proper cooling of the converter is provided.

A reduction in the operating temperature of the converter will result in an increased reliability.

Thermal Derating

There are two most common applications: 1) the FXW converter is thermally attached to a cold plate inside chassis without any forced internal air circulation; 2) the FXW converter is mounted in an open chassis on system board with forced airflow with or without an additional heatsink attached to the base plate of the FXW converter.

The best thermal results are achieved in application 1) since the converter is cooled entirely by conduction of heat

from the top surface of the converter to a cold plate and temperature of the components is determined by the temperature of the cold plate. There is also some additional heat removal through the converter’s pins to the metal layers in the system board. It is highly recommended to solder pins to the system board rather than using receptacles. Typical derating output power and current are shown in Figs. 17–26 for various baseplate temperatures up to 105ºC. Note that operating converter at these limits for prolonged time will affect reliability.

Soldering Guidelines

The ROHS-compliant through-hole FXW converters use Sn/Ag/Cu Pb-free solder and ROHS-compliant component. They are designed to be processed through wave soldering machines. The pins are 100% matte tin over nickel plated and compatible with both Pb and Pb-free wave soldering processes. It is recommended to follow specifications below when installing and soldering FXW converters. Exceeding these specifications may cause damage to the FXW converter.

Wave Solder Guideline For Sn/Ag/Cu based solders

Maximum Preheat Temperature 115 ºC

Maximum Pot Temperature 270 ºC

Maximum Solder Dwell Time 7 seconds

Wave Solder Guideline For Sn/Pb based solders

Maximum Preheat Temperature 105 ºC

Maximum Pot Temperature 250 ºC

Maximum Solder Dwell Time 6 seconds

FXW converters are not recommended for water wash process. Contact the factory for additional information if water wash is necessary.


DC/DC Converters


Test Configuration

Fig. 5: Test setup for measuring iput reflected ripple currents iC

Fig. 6: Test setup for measuring output voltage ripple, startup and step load transient waveforms

Ref. Des. Manufacturing p/n 24S12.84FXW24S24.42FXW 24S28.36FXW

24S48.21FXW24S53.19FXW

L1 N/A 6 ft. cable, AWG 4 100nH 100nH

CIN MAL214699108E3 (Vishay)2 x 470 µF / 72mΩ

(650mΩ)2 x 470 µF / 72mΩ

(650mΩ)2 x 470 µF / 76mΩ

(650mΩ)

C1 GRM32ER72A475KA12L 10 µF / 1210 / X7R / 100v 10 µF / 1210/X7R/100V 10 µF / 1210 / X7R / 100V

C2

PCR1E471MCL1GS3 X 470 µF/ 25V / 15 mΩ

(30 mΩ) N/A N/A

PCR1J101MCL1GS (Nichicon) N/A3 x 100 µF / 63V / 24 mΩ

(48 mΩ)N/A

PCR1K680MCL1GS (Nichicon) N/A N/A3 x 68 µF / 80V / 28 mΩ

(56 mΩ)

UPS2A221MPD (Nichicon) N/A 220 µF / 100V / 100mΩ 220 µF / 100V / 100mΩ

MAL214699108E3 (Vishay) N/A 470 µF / 72mΩ (650mΩ) N/A

MAL214699606E3 (Vishay)2 X 1500 µF / 50mΩ

(450mΩ)N/A N/A

MAL214699608E3 (Vishay 2200 µF / 50mΩ (450mΩ) N/A N/A

Table 1: Component values used in test setup from Figs. 5 and 6. Resistance in ( ) represents ESR value at -40°C for specified capacitor.


DC/DC Converters


Characteristic Curves – Efficiency and Power Dissipation

Fig. 7: 24S12.84FXW (ROHS) Efficiency Curve Fig. 8: 24S12.84FXW (ROHS) Power Dissipation




DC/DC Converters


Characteristic Curves – Efficiency and Power Dissipation (Cont’d)




DC/DC Converters


Characteristic Curves – Derating Curves

Fig. 17: 24S12.84FXW (ROHS) Derating Curve Fig. 18: 24S12.84FXW (ROHS) Derating Curve

0

100

200

300

400

500

600

700

800

900

1000

1100

25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105

Out

put P

ower

[W]

Baseplate Temperature [C]

Output Power vs. Base Plate Temperature - 24S24.42FXW

Vin=9V Vin=12V, 24V, 36V

0

4

8

12

16

20

24

28

32

36

40

44

25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105

Out

put C

urre

nt [W

]


Output Current vs. Base Plate Temperature - 24S24.42FXW



0

100

200

300

400

500

600

700

800

900

1000

1100

25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105

Out

put P

ower

[W]


Output Power vs. Base Plate Temperature - 24S28.36 XW


0

4

8

12

16

20

24

28

32

36

40

25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105

Out

put C

urre

nt [W

]






DC/DC Converters


Characteristic Curves – Derating Curves (Cont’d)

0

100

200

300

400

500

600

700

800

900

1000

1100

25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105

Out

put P

ower

[W]




0

2

4

6

8

10

12

14

16

18

20

22

25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105

Out

put C

urre

nt [W

]





0

100

200

300

400

500

600

700

800

900

1000

1100

25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105

Out

put P

ower

[W]




0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

16.0

18.0

20.0

25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105

Out

put C

urre

nt [W

]






DC/DC Converters


Characteristic Waveforms – 24S12.84FXW

Fig. 27: Turn-on by ON/OFF transient (with Vin applied) at full rated load current (resistive) at Vin = 14V. Top

trace (C1): ON/OFF signal (5 V/div.). Bottom trace (C4): Output voltage (5 V/div.). Time: 10 ms/div.

Fig. 28: Turn-on by Vin transient (ON/OFF high) at full rated load current (resistive) at Vin = 44V. Top trace (C2):

Input voltage Vin (5 V/div.). Bottom trace (C4): Output voltage (5 V/div.). Time: 100 ms/div.

Fig. 29: Output voltage response to load current step change 70% - 100%- 70% (58.5A–84A–58.8A) with di/dt =0.5A/µs at Vin = 14V . Top trace (C4): Output voltage (200 mV/div.). Bottom trace (C3): Load current (50A/div.).

Time: 1ms/div.

Fig. 30: Output voltage response to load current step change 50% - 100%- 50% (42A–84A–42A) with di/

dt =1A/µs at Vin = 14 V. Top trace (C4): Output voltage (500 mV/div.). Bottom trace (C3): Load current (50A/div.).

Time: 1ms/div.

Fig. 31: Output voltage ripple (100 mV/div.) at full rated load current into a resistive load at Vin = 14 V. Time: 2 µs/

div

Fig. 32: Input reflected ripple current, ic (500mA/mV), measured at input terminals at full rated load current at Vin = 24 V. Refer to Fig. 2 for test setup. Time: 2 µs/div.

RMS input ripple current is 7.3*0.5A = 3.65ARMS.


DC/DC Converters



Fig. 33: Turn-on by ON/OFF transient (with Vin applied) at full rated load current (resistive) at Vin = 24V. Top

trace (C1): ON/OFF signal (5 V/div.). Bottom trace (C4): Output voltage (10 V/div.). Time: 5 ms/div.

Fig. 34: Turn-on by Vin transient (ON/OFF high) at full rated load current (resistive) at Vin = 24V. Top trace (C2): Input voltage Vin (10 V/div.). Bottom trace (C4): Output

voltage (10 V/div.). Time: 100 ms/div.

Fig. 35: Output voltage response to load current step change 50% - 75%- 50% (21A–31.5A–21A) with di/

dt =1A/µs at Vin = 24V . Top trace (C4): Output voltage (200 mV/div.). Bottom trace (C3): Load current (20A/div.).

Co = 470µF/70mΩ. Time: 1ms/div.

Fig. 36: Output voltage response to load current step change 50% - 100%- 50% (21A–42A–21A) with di/dt

=1A/µs at Vin = 24 V. Top trace (C4): Output voltage (500 mV/div.). Bottom trace (C3): Load current (20A/div.). Co =

2 x 470 µF/70mΩ. Time: 1ms/div.

cFig. 37: Output voltage ripple (100 mV/div.) at full rated load current into a resistive load at Vin = 24 V. Co = 2 x

470 µF/70mΩ. Time: 2 µs/div.

Fig. 38: Input reflected ripple current, ic (500mA/mV), measured at input terminals at full rated load current at Vin = 24 V. Refer to Fig. 2 for test setup. Time: 2 µs/div.



DC/DC Converters



Fig. 39: Turn-on by ON/OFF transient (Vin applied) at full rated load current (resistive) at Vin = 24V. Top trace

(C1): ON/OFF signal (5 V/div.). Bottom trace (C4): Output voltage (10 V/div.). Time: 5 ms/div.

Fig. 40: Turn-on by Vin (ON/OFF high) transient at full rated load current (resistive) at Vin = 24V. Top trace (C2): Input voltage Vin (10 V/div.). Bottom trace (C4): Output


Fig. 41: Output voltage response to load current step change 50% - 75%- 50% (18A–27A–18A) with di/dt

=1A/µs at Vin = 24V . Top trace (C4): Output voltage (200 mV/div.). Bottom trace (C3): Load current (10A/div.). Co =

470µF/70mΩ. Time: 1ms/div.

Fig. 42: Output voltage response to load current step change 50% - 100%- 50% (18A–36A–18A) with di/

dt =1A/µs at Vin = 24V . Top trace (C4): Output voltage (500 mV/div.). Bottom trace (C3): Load current (10A/

div.). Co = 470 µF/70mΩ. Time: 1ms/div.

cFig. 43: Output voltage ripple (100 mV/div.) at full rated load current into a resistive load at Vin = 24 V. Co = 470

µF/70mΩ. Time: 2 µs/div.

Fig. 44: Input reflected ripple current, ic (500 mA/div.), measured at input terminals at full rated load current at Vin = 24 V. Refer to Fig. 2 for test setup. Time: 2 µs/div.



DC/DC Converters




(C1): ON/OFF signal (5 V/div.). Bottom trace (C4): Output voltage (10 V/div.). Time: 10 ms/div..



Fig. 47: Output voltage response to load current step change 50% - 75%- 50% (10.5A–15.75A–10.5A)

with di/dt =1A/µs at Vin = 24V . Top trace (C4): Output voltage (200 mV/div.). Bottom trace (C3): Load current

(10A/div.).. Time: 1ms/div

Fig. 48: Output voltage response to load current step change 50% - 100%- 50% (10.5A–21A–10.5A) with di/dt =1A/µs at Vin = 24V . Top trace (C4): Output voltage

(500 mV/div.). Bottom trace (C3): Load current (10A/div.). Time: 1ms/div.

cFig. 49: Output voltage ripple (100 mV/div.) at full rated

load current into a resistive load at Vin = 24 V. Time: 2 µs/div.


RMS input ripple current is 7.3*0.5A = 3.65ARMS..


DC/DC Converters




(C1): ON/OFF signal (5 V/div.). Bottom trace (C4): Output voltage (10 V/div.). Time: 10 ms/div.



Fig. 53: Output voltage response to load current step change 50% - 75%- 50% (9.5A–14.25A–9.5A) with di/dt =1A/µs at Vin = 24V . Top trace (C4): Output voltage (200 mV/div.). Bottom trace (C3): Load current (10A/

div.).. Time: 1ms/div.

Fig. 54: Output voltage response to load current step change 50% - 100%- 50% (9.5A–19A–9.5A) with di/

dt =1A/µs at Vin = 24V . Top trace (C4): Output voltage (500 mV/div.). Bottom trace (C3): Load current (10A/div.).

Time: 1ms/div.

cFig. 55: Output voltage ripple (100 mV/div.) at full rated

load current into a resistive load at Vin = 24 V. Time: 2 µs/div.




DC/DC Converters


EMC Consideration

The filter circuit schematic for suggested input filter configuration as tested to meet the conducted emission limits of MILSTD-461F CE102 Base Curve is shown in Fig. 57. The plots of conducted EMI spectrum measured using 5uH LISNs are shown in Fig. 58.

Note: Customer is ultimately responsible for the proper selection, component rating and verification of the suggested parts based on the end application.

Component Designator Description

C1, C2, C12, C14 470uF/50V/70mΩ Electrolytic Capacitor (Vishay MAL214699108E3 or equivalent)

C3, C4, C5, C6 4.7nF/1210/X7R/1500V Ceramic Capacitor

C7, C8, C9, C10, C11, C13 10µF/1210/X7R/50V Ceramic Capacitor

L1 CM choke, 130µH, Leakage = 0.6µH (4T on toroid 22.1mm x 13.7 mm x 7.92 mm)

Fig. 57: Typical input EMI filter circuit to attenuate conducted emissions per MILSTD-461F CE102 Base Curve.

a) Without input filter from Fig. 47 (C9 = 2 x 470µF/50V/70mΩ)

b) With input filter from Fig. 47.

Fig. 58: Input conducted emissions measurement (Typ.) of 24S24.42FXW.

© Calex Manufacturing Company, Inc., a division of Murata Power Solutions • +1 (925) 687-4411 • (800) 542-3355 • e-mail: [email protected]

Calex Manufacturing, Inc. (“Calex”) makes no representation that the use of its products in the circuits described herein, or the use of other technical information contained herein, will not infringe upon existing or future patent rights. The descriptions contained herein do not imply the granting of licenses to make, use, or sell equipment constructed in accordance therewith. Buyer represents and agrees that it has all the necessary expertise to create and implement safeguards that anticipate dangerous consequences of failures, monitor failures and their consequences, lessen the likelihood of failures that might cause harm, and take appropriate remedial actions. Buyer will fully indemnify Calex, its affiliated companies, and its representatives against any damages arising out of the use of any Calex products in safety-critical applications. Specifications are subject to change without notice. FXW.A01 26

FXW Series, 1000 WattDC/DC Converters

Mechanical Specification

Input/ Output Connections

Pin Label Function Pin Label Function

1 +ON/OFF TTL input with internal pull up, referenced to –-ON/OFF pin, used to turn converter on and off 6 +OUT Positive Output Voltage

2 -ON/OFF Negative input of Remote ON/OFF 8 -OUT Negative Output Voltage

3 -INPUT Negative Input Voltage 9 -OUT Negative Output Voltage

3A -INPUT Negative Input Voltage 10 SENSE- Negative Remote Sense

4 +INPUT Positive Input Voltage 11 SENSE+ Positive Remote Sense

4A +INPUT Positive Input Voltage 12 TRIM Used to Trim outlput voltage +10/-40%

5 +OUT Positive Output Voltage

Note:

1) Pinout as well as pin number and pin diameter are inconsistent between manufacturers of the full brick converters. Make sure to follow the pin function, not the pin number as well as spec for pin diameter when laying out your board.

NOTES:

Unless otherwise specified: All dimensions are in inches [millimeter Tolerances: x.xx in. ±0.02 in. [x.x mm ± 0.5mm] x.xxx in. ±0.010 in. [x.xx mm ± 0.25mm]

Torque fasteners into threaded mounting inserts at 10 in.lbs. or less. Greater torque may result in damage to unit and void the warranty.

[email protected] +1 (925) 687-4411over load vin = 24v, load 0% to 100% 0.05 0.10 % temperature...

Documents